Micro-electromechanical systems (MEMS) microphone and method of manufacturing the same

ABSTRACT

Provided are a micro-electromechanical systems (MEMS) microphone and a method of manufacturing the same. A manufacturing process is simplified compared to a conventional art using both upper and lower substrate processes. Since defects which may occur during manufacturing are reduced due to the simplified manufacturing process, the manufacturing throughput is improved, and since durability of the MEMS microphone is improved, system stability against the external environment is improved.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No. 12/509,411, filed on Jul. 24, 2009, now U.S. Pat. No. 8,175,300.

This application claims priority to and the benefit of Korean Patent Application No. 10-2008-0131632, filed Dec. 22, 2008, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

1. Field of the Invention

The present invention relates to a micro-electromechanical systems (MEMS) microphone and a method of manufacturing the same, and more particularly to a MEMS microphone which can be simply manufactured through an upper substrate process and a method of manufacturing the same.

2. Discussion of Related Art

A microphone is an apparatus which converts a voice into an electrical signal. Types of microphones include a dynamic type, a condenser type, a ribbon type, and a ceramic type. As electrical or electronic technology develops rapidly, microphone technology is also greatly improved, and as development of small-sized wireless or wire line devices is accelerated, the size of microphones is also gradually decreasing. In this regard, a micro-electromechanical systems (MEMS) microphone using MEMS technology has been recently developed.

MEMS microphones can be generally divided into a piezo type and a condenser type. The condenser-type MEMS microphone is more frequently used due to an excellent frequency response characteristic of a voice band.

FIG. 1 illustrates a conventional condenser-type MEMS microphone.

Referring to FIG. 1, a condenser-type MEMS microphone 100 is manufactured by an upper substrate process of forming a lower electrode 130 and a diaphragm 170 in an upper portion of a substrate 110 and a lower substrate process of forming a rear acoustic chamber 190 in a lower portion of the substrate 110.

First, in the upper substrate process, the lower electrode 130 is formed on the substrate 110, and a sacrificial layer-removing lower electrode hole 130 a is formed in the lower electrode 130. A sacrificial layer 150 is formed on the lower electrode 130 at a predetermined thickness, and the diaphragm 170 is formed on the sacrificial layer 150. The diaphragm 170 includes an insulating layer 171 and an upper electrode 173, and is fixed to the substrate 110 by a diaphragm support 170 a.

Next, in the lower substrate process, after the diaphragm 170 is formed on the substrate 110, the upper portion of the substrate 110 is protected by an insular, and a lower portion of the substrate 110 is etched through bulk-type micromachining to form a rear acoustic chamber 190. Then, the sacrificial layer 150 is removed through the lower electrode hole 130 a to form a vibration cavity 150 a.

As described above, according to the conventional art, since the lower substrate process is required in order to form the rear acoustic chamber 190, the manufacturing process is complicated. Therefore, there is a problem in that there is a limitation to increasing manufacturing throughput.

SUMMARY OF THE INVENTION

The present invention is directed to a MEMS microphone which can be simply manufactured through an upper substrate process and a method of manufacturing the same.

One aspect of the present invention provides a micro-electromechanical systems (MEMS) microphone, including: a substrate; a rear acoustic chamber formed inside the substrate; a lower electrode formed above the substrate and including first and second rear acoustic chamber vent holes through which the rear acoustic chamber is formed; and a diaphragm formed to have a vibration cavity between with the lower electrode and including a side hole for removing a sacrificial layer to form the vibration cavity.

The rear acoustic chamber may have a well-shaped cross section.

A lower insulating layer may be formed between the lower electrode and the substrate.

The first rear acoustic chamber vent hole may be formed to penetrate the lower electrode and the lower insulating layer inside the lower electrode, the second rear acoustic chamber vent hole may be formed to extend from the inside of the lower electrode to the outside and penetrate the lower electrode and the lower insulating layer, and a predetermined surface portion of the substrate may be exposed by the first and second rear acoustic chamber vent holes.

The diaphragm may be fixed to the substrate by a diaphragm support which is formed such that a predetermined portion of the diaphragm extends to the substrate.

The side hole may be an empty space between the diaphragm supports.

The side hole may be formed at a location corresponding to the second rear acoustic chamber vent hole.

A lower electrode support which supports the lower electrode may be formed inside the substrate.

An attenuation coefficient may be adjusted depending on the size and number of the first and second rear acoustic chamber vent holes.

Another aspect of the present invention provides a method of manufacturing a micro-electromechanical systems (MEMS) microphone, the method including: sequentially forming a lower insulating layer and a lower electrode on a substrate; etching portions of the lower insulating layer and the lower electrode to form first and second rear acoustic chamber vent holes through which a rear acoustic chamber is formed; forming a sacrificial layer on the lower electrode; forming a diaphragm including a diaphragm support and a side hole for removing the sacrificial layer on the sacrificial layer; etching the sacrificial layer through the side hole to form a vibration cavity; and etching the inside of the substrate at a predetermined depth through the first and second rear acoustic chamber vent holes to form the rear acoustic chamber.

Sequentially forming the lower insulating layer and the lower electrode may include forming the lower insulating layer on the substrate, and then forming the lower electrode on a central portion of the lower insulating layer.

Etching the portions of the lower insulating layer and the lower electrode may include forming the first and second rear acoustic chamber vent holes to penetrate the lower insulating layer and the lower electrode while exposing predetermined surface portions of the substrate.

Etching the portions of the lower insulating layer and the lower electrode may include: forming the first rear acoustic chamber vent hole which penetrates the lower insulating layer and the lower electrode inside the lower electrode; and forming the second rear acoustic chamber vent hole which extends from the inside of the lower electrode to the outside and penetrates the lower insulating layer and the lower electrode.

Forming the diaphragm may include forming a diaphragm support in which a predetermined portion of the diaphragm extends to the substrate while forming the side hole in an empty space between with the diaphragm support.

Forming the diaphragm may include forming the side hole at a location corresponding to the second rear acoustic chamber vent hole.

Etching the sacrificial layer may include etching the sacrificial layer through the side hole using a surface micromachining process technique to form the vibration cavity.

Etching the inside of the substrate may include etching the inside of the substrate at a predetermined depth centering on the first and second rear acoustic chamber vent holes using a surface micromachining process technique or a dry-etching technique to form the rear acoustic chamber.

The inside of the substrate may be etched through the first and second rear acoustic chamber vent holes so that the rear acoustic chamber has a well-shaped cross section.

A lower electrode support which supports the lower electrode may be formed inside the substrate by etching the inside of the substrate through the first and second rear acoustic chamber vent holes.

An attenuation coefficient of the diaphragm may be adjusted by adjusting the size and number of the first and second rear acoustic chamber vent holes.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing in detail preferred embodiments thereof with reference to the attached drawings in which:

FIG. 1 is a cross-sectional view illustrating a conventional condenser-type MEMS microphone;

FIGS. 2A and 2B are cross-sectional views illustrating a structure of a MEMS microphone according to an exemplary embodiment of the present invention;

FIGS. 3A to 3K are cross-sectional views illustrating a method of manufacturing a MEMS microphone according to an exemplary embodiment of the present invention;

FIG. 4 is a view for describing first and second rear acoustic vent holes through which a rear acoustic chamber is formed in a MEMS microphone according to an exemplary embodiment of the present invention; and

FIG. 5 is a view for describing a diaphragm including a diaphragm support and a sacrificial layer-removing side hole in a MEMS microphone according to an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Hereinafter, exemplary embodiments of the present invention will be described in detail. However, the present invention is not limited to the embodiments disclosed below, but can be implemented in various forms. Therefore, the following embodiments are described in order for this disclosure to be complete and enabling to those of ordinary skill in the art.

FIGS. 2A and 2B are cross-sectional views, taken at different angles, illustrating a structure of a micro-electromechanical systems (MEMS) microphone 200 according to an exemplary embodiment of the present invention.

Referring to FIGS. 2A and 2B, the MEMS microphone 200 according to an exemplary embodiment of the present invention includes a substrate 210 in which a rear acoustic chamber 210 a and a lower electrode support 210 b are formed, a lower insulating layer 220 formed on the substrate 210, a lower electrode 230 formed on a central portion of the lower insulating layer 220, and a diaphragm 270 formed above the lower electrode 230 with a vibration cavity 250 a therebetween.

Particularly, the rear acoustic chamber 210 a having a well-shaped cross section and the lower electrode support 210 b for supporting the lower electrode 230 are formed inside the substrate 210, and first and second rear acoustic chamber vent holes 240 a and 240 b through which the rear acoustic chamber 210 a is formed are formed above the rear acoustic chamber 210 a.

The first and second rear acoustic vent holes 240 a and 240 b serve not only to form the rear acoustic chamber 210 a but also to improve an attenuation coefficient of the diaphragm 270 to thereby improve a frequency response characteristic.

That is, in the conventional condenser-type MEMS microphone 100, the rear acoustic chamber 190 is formed in the lower portion of the substrate 110, but in the MEMS microphone 200 according to an exemplary embodiment of the present invention, the rear acoustic chamber 210 a is formed inside the substrate 210.

The rear acoustic chamber 210 a can be formed inside the substrate 210 because a sacrificial layer 250 can be etched through a sacrificial layer-removing side hole 270 b formed on a predetermined side of the diaphragm 270, which will be described below in further detail.

A method of manufacturing the MEMS microphone 200 according to an exemplary embodiment of the present invention will be described below in further detail.

FIGS. 3A to 3K are cross-sectional views illustrating a method of manufacturing the MEMS microphone 200 according to an exemplary embodiment of the present invention.

First, as shown in FIG. 3A, the lower insulating layer 220 is formed on the substrate 210, and the lower electrode 230 is formed on a central portion of the lower insulating layer 220.

Then, as shown in FIGS. 3B and 3C, the first and second rear acoustic chamber vent holes 240 a and 240 b are formed to penetrate the lower electrode 230 and the lower insulating layer 220.

The first and second area acoustic chamber vent holes 240 a and 240 b are holes used to etch the inside of the substrate in order to form the rear acoustic chamber 210 a and will be described below in further detail with reference to FIG. 4.

FIG. 4 is a view for describing the first and second rear acoustic vent holes 240 a and 240 b through which the rear acoustic chamber 210 a is formed in the MEMS microphone 200 according to an exemplary embodiment of the present invention. FIG. 3B is a cross-sectional view taken along line A1-A2 of FIG. 4, and FIG. 3C is a cross-sectional view taken along line B1-B2 of FIG. 4.

Referring to FIG. 4, a predetermined number of the first and second rear acoustic vent holes 240 a and 240 b which penetrate the lower electrode 230 and the lower insulating layer 220 are formed at a predetermined interval.

The first rear acoustic chamber vent hole 240 a is formed inside the lower electrode 230 to expose a predetermined surface portion of the substrate 210, and the second rear acoustic chamber vent hole 240 b is formed to extend from the inside of the lower electrode 230 to the outside thereof to expose a predetermined surface portion of the substrate 210.

The second rear acoustic chamber vent hole 240 b is formed to extend to the outside of the lower electrode 230 so that the inside of the substrate 210 can be more easily etched and processed when forming the rear acoustic chamber 210 a.

Since an attenuation coefficient of the diaphragm 270 which will be formed later may depend on the size and number of the first and second rear acoustic chamber vent holes 240 a and 240 b, the attenuation coefficient of the diaphragm 270 may be adjusted by adjusting the size and number of the first and second rear acoustic chamber vent holes 240 a and 240 b to thereby improve the frequency response characteristic.

Next, as shown in FIG. 3D, the sacrificial layer 250 is formed on the substrate 210 on which the lower insulating layer 220 and the lower electrode 230 are sequentially stacked.

Subsequently, as shown in FIGS. 3E to 3G, an insulating layer 271 and an upper electrode 273 are sequentially stacked on the sacrificial layer 250 to form the diaphragm 270.

At this time, the diaphragm support 270 a for fixing the diaphragm 270 to the substrate 210 and the sacrificial layer-removing side hole 270 b for etching of the sacrificial layer 250 are formed together.

The diaphragm support 270 a is formed such that the diaphragm 270 extends to the substrate along the side of the sacrificial layer 250. At this time, an area in which the diaphragm 270 does not extend to the substrate 210 is defined as the sacrificial layer-removing side hole 270 b.

The diaphragm support 270 a and the sacrificial layer-removing side hole 270 b will be described below in further detail with reference to FIG. 5.

FIG. 5 is a view for describing the diaphragm 270 including the diaphragm support 270 a and the sacrificial layer-removing side hole 270 b in the MEMS microphone 200 according to an exemplary embodiment of the present invention. FIG. 3E is a cross-sectional view taken along line C1-C2 of FIG. 5, FIG. 3F is a cross-sectional view taken along line D1-D2 of FIG. 5, and FIG. 3G is a cross-sectional view taken along line E1-E2 of FIG. 5.

Referring to FIG. 5, the diaphragm support 270 a extends to the substrate 210 to fix the diaphragm 270 to the substrate 210, and an empty space between the diaphragm supports 270 a, that is, an area in which the diaphragm support 270 a is not formed, serves as the sacrificial layer-removing side hole 270 b.

The sacrificial layer-removing side hole 270 b is preferably formed at a location corresponding to the second rear acoustic chamber vent hole 240 b. This is because the inside of the substrate 210 can be more easily etched and processed when forming the rear acoustic chamber 210.

Then, the sacrificial layer 250 is removed through the sacrificial layer-removing side hole 270 a using a surface micromachining process (see FIGS. 3F and 3G) to thereby form the vibration cavity 250 a in which the diaphragm 270 can freely vibrate as shown in FIGS. 3H and 3I.

Also, through the process described above, as shown in FIGS. 3H and 3I, the first and second rear acoustic chamber vent holes 240 a and 240 b for forming the rear acoustic chamber 210 a are exposed.

Finally, as shown in FIGS. 3J and 3K, the inside of the substrate 210 corresponding to the first and second rear acoustic chamber vent holes 240 a and 240 b is etched using a surface micromachining process to thereby form the rear acoustic chamber 210 a which has a well-shaped cross section inside the substrate 210.

At this time, as shown in FIGS. 3J and 3K, since the side is opened through the sacrificial layer-removing side hole 270 b, the inside of the substrate 210 can be easily etched through the first and second rear acoustic chamber vent holes 240 a and 240 b. Particularly, since the width of the second rear acoustic chamber vent hole 240 b is wider than the width of the first rear acoustic chamber vent hole 240 a, the inside of the substrate 210 can be more easily etched through the second rear acoustic chamber vent hole 240 b.

As the inside of the substrate 210 is etched through the first and second rear acoustic chamber vent holes 240 a and 240 b, a lower electrode support 210 b for supporting the lower electrode 230 is formed inside the substrate 210.

The size of the rear acoustic chamber 210 a formed through the process described above depends on the overall area size of the lower electrode 230 which detects a variation of capacitance, and the depth thereof depends on the maximum depth at which the lower electrode support 210 b which supports the lower electrode 230 at a regular interval can be formed.

In the present embodiment, the rear acoustic chamber 210 a is formed through the first and second rear acoustic chamber vent holes 240 a and 240 b using a surface micromachining process, but the rear acoustic chamber 210 a may be formed using a dry-etching technique without a separate mask process.

As described above, according to the conventional art, the lower substrate process is indispensably required in order to form the rear acoustic chamber 190, but according to an exemplary embodiment of the present invention, the rear acoustic chamber 210 a can be simply manufactured only through the upper substrate process using the first and second rear acoustic chamber vent holes 240 a and 240 b.

As described above, according to the present invention, since the MEMS microphone can be manufactured only through the upper substrate process, the manufacturing process can be simplified compared to the conventional art using both the upper substrate process and the lower substrate process, and defects which may occur during manufacturing can be reduced, leading to high manufacturing throughput.

Also, since durability of the MEMS microphone is increased by the lower electrode support 210 b, system stability against the external environment is improved, and since an attenuation coefficient of the diaphragm 270 can be improved by the first and second rear acoustic chamber vent holes 240 a and 240 b, the frequency response characteristic can be improved.

According to exemplary embodiments of the present invention, since the MEMS microphone can be manufactured through the upper substrate process, the manufacturing process is simple compared to the conventional art using both the upper substrate process and the lower substrate process.

Due to the simplified manufacturing process, defects which may occur during manufacturing can be reduced, leading to high manufacturing throughput. Since durability of the MEMS microphone is improved, system stability against the external environment can be also improved.

In addition, since an attenuation coefficient of a diaphragm can be improved by the rear acoustic chamber vent holes formed in the lower electrode, the frequency response characteristic can be improved.

While the invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. 

What is claimed is:
 1. A method of manufacturing a micro-electromechanical systems (MEMS) microphone, the method comprising: sequentially forming a lower insulating layer and a lower electrode on a substrate; etching portions of the lower insulating layer and the lower electrode to form first and second rear acoustic chamber vent holes through which a rear acoustic chamber is formed; forming a sacrificial layer on the lower electrode; forming a diaphragm including a diaphragm support and a side hole for removing the sacrificial layer on the sacrificial layer; etching the sacrificial layer through the side hole to form a vibration cavity; and etching the inside of the substrate at a predetermined depth through the first and second rear acoustic chamber vent holes to form the rear acoustic chamber.
 2. The method of claim 1, wherein the sequentially forming of the lower insulating layer and the lower electrode comprises forming the lower insulating layer on the substrate, and then forming the lower electrode on a central portion of the lower insulating layer.
 3. The method of claim 1, wherein the etching of the portions of the lower insulating layer and the lower electrode comprises forming the first and second rear acoustic chamber vent holes to penetrate the lower insulating layer and the lower electrode while exposing predetermined surface portions of the substrate.
 4. The method of claim 3, wherein the etching of the portions of the lower insulating layer and the lower electrode comprises: forming the first rear acoustic chamber vent hole which penetrates the lower insulating layer and the lower electrode inside the lower electrode; and forming the second rear acoustic chamber vent hole which extends from the inside of the lower electrode to the outside and penetrates the lower insulating layer and the lower electrode.
 5. The method of claim 1, wherein the forming of the diaphragm comprises forming a diaphragm support in which a predetermined portion of the diaphragm extends to the substrate while forming the side hole in an empty space between the diaphragm supports.
 6. The method of claim 5, wherein the forming of the diaphragm comprises forming the side hole at a location corresponding to the second rear acoustic chamber vent hole.
 7. The method of claim 1, wherein the etching of the sacrificial layer comprises etching the sacrificial layer through the side hole using a surface micromachining process technique to form the vibration cavity.
 8. The method of claim 1, wherein the etching of the inside of the substrate comprises etching the inside of the substrate at a predetermined depth centering on the first and second rear acoustic chamber vent holes using a surface micromachining process technique or a dry-etching technique to form the rear acoustic chamber.
 9. The method of claim 8, wherein the inside of the substrate is etched through the first and second rear acoustic chamber vent holes so that the rear acoustic chamber has a well-shaped cross section.
 10. The method of claim 9, further comprising forming a lower electrode support which supports the lower electrode inside the substrate by etching the inside of the substrate through the first and second rear acoustic chamber vent holes.
 11. The method of claim 1, further comprising adjusting the size and number of the first and second rear acoustic chamber vent holes to adjust an attenuation coefficient of the diaphragm. 